P14471 Vibration Testing Application

Team Introductions NameRoleMajor Brett BillingsTeam LeaderIndustrial Engineer Nick GrecoLead EngineerMechanical Engineer Ashley WaldronScribeMechanical Engineer Claire KobalEDGE MasterMechanical Engineer Jacob GardnerMechanical Engineer Ron JimboElectrical Engineer Ryan SeligElectrical Engineer

Agenda Background System Analysis Alternatives considered Selected system Test Plan Engineering Analysis Next Phase

Problem Statement Update company’s vibration test apparatus Meet UL 844 Standard Vibration RPM Displacement Duration Continue progress started by Team Done: the eccentric drive mechanism Still needs: Frame Motor Control system

Project Deliverables Completed frame Appropriate motor selection and implementation Motor speed control alternatives Visual display Frequency of oscillation Displacement Documentation User Manual Maintenance Manual Test data verifying the operation of the apparatus

Customers Needs RequirementsImportance Adherence to UL 844 standard5 Apparatus is safe5 Motor must be compatible with available voltage5 Ability to test a range of luminaire weights4 Long service life4 Ability to test multiple configurations3 Easy to use3 Visually display test information/feedback to operator3 Cost under $4,0003 Easy to maintain2 Similar dimensions to existing machine1

Engineering Requirements NumberRequirement Raw Score Units Ideal Measure 1 Displacement of luminaire69in1/32 2 Vibration of luminaire69cycles/min Duration of vibration test69hours35 4 Isolate motor from oil spills45BinaryYes 5 Maintenance Documentation44Survey (easy to follow)80% 6 Mount pendant configuration35BinaryYes 7 Operation Documentation33Survey (easy to follow)80% 8 Machine won't operate if crankshaft enclosure is open25BinaryYes 9 Completely stop machine with Emergency Stop25seconds< Maximum voltage of Motor25V AC Minimize number of operators21people2 12 Max weight of mounted luminaire20lbs> Visually display settings and status of test18BinaryYes 14 Steps to set up16steps< Setup Time16seconds< Low Sound15dBA< Minimize pinch points15Count< 3 18 Total materials cost15$< 4, Mount stanchion configuration7BinaryYes 20 Mount yoke configuration7BinaryYes 21 Mount trunnion configuration7BinaryYes 22 Machine footprint5in 2 < 34X48

Engineering Requirements: The Design Drivers

Benchmarking Current ModelOur Design Displacement MechanismOpenEncased Motor MountingBelow shaftOffset BrakeNoneBetween shaft and motor DisplayNoneDigital Displacement measurementNone+/-.5µm

Functional Decomposition

Risk Assessment

Morph Chart Overview

Alternatives Considered: Consider Systems Level

Alternatives Considered:

Consider Systems Level

Morph Chart (Option 1) Screws Vertical Motor with Belt Laser Software LED Screen Ear Plugs Belt Guard + Guard Plate Electroplating

Morph Chart (Option 2) Screws Vertical Motor with Speed Reducer Laser Software LED Screen Ear Plugs Guard Plate Spray Paint

Morph Chart (Option 3) Screws Horizontal Motor with Flexible, Speed Reducing Coupling Laser Software LED Screen Enclosure Spray Paint

System Pugh Chart Why? Paint

Selected Concept

Risk Assessment of Selected Concept

Architecture Central System Power supplyMotor system Sensors Display/user interface Luminaire connection Crankshaft connection Safety features

Test Plan Test Displacement Validate the 1/32” total displacement Test Vibration Cycles Validate 2000 cycles/min Test fittings Do they fit the frame? Test User Interface Check connections Ease of use Safety Evaluation

Engineering Analysis: Frame Analysis Modeling frame in ANSYS Workbench Using Modal Analysis to determine Natural Frequency Next, stress and fatigue analyses will be performed on frame Goal: 1. Prevent resonance in the frame 2. Prevent material failure 3. Prevent fatigue at connections

Engineering Analysis: Motor A v-belt speed reducing system was selected because of its ability to provide the torque and speed necessary to run the machine at the standard and because of cost. A direct coupling would have needed a 3500 RPM motor to run at less than 60% speed for 35 hrs at a time. This just isn’t possible with most motors. Most speed reducing apparatuses are used to drastically increase torque output and don’t provide the speed ratio needed to run the crankshaft at 2000 RPM. They are also much more expensive than the belt system. Concept: Because of an increase in the radius, the driven pulley will be able to rotate at 2000 RPM while the driver pulley rotates at 3500 RPM when the proper ratio of radii is selected.

Engineering Analysis: Control System Open Loop System Closed Loop System

Engineering Analysis: Open Loop Control System Two component system: User input Motor speed control Multiple methods to control speed output: Vary input voltage to the motor Alter frequency of input signal to the motor Change the number of stator poles

Engineering Analysis: Closed Loop Control System Cycles per minute directly proportional to RPM Three core components required for control: Vibration speed sensor Motor speed correction Motor speed controller Laser distance sensor to simultaneously measure vibration speed and displacement Variable-Frequency Drive (VFD) to adjust speed Microcontroller to accept sensor output measurement and feed corrected motor speed into VFD Digital display for reading back measurements

Engineering Analysis: Closed Loop Feedback Laser Feedback System Accuracy & precision on order of microns Measurement frequency on order of kilohertz Line of sight coincident with linear motion Accurately sense each 1/32" displacement Two consecutive changes in distance = 1 cycle Analog output to feed into corrective circuit

Engineering Analysis: Control System Comparison Open Loop System Requires user input to adjust motor speed Does not self correct with changing loads Does not require a feedback system Simple design to implement Closed Loop System Self correcting (no user input required) Higher design budget Integrates measuring devices with control system

Engineering Analysis: Sound L = dbA Sound Level T = 8 hour exposure limit C = actual exposure hours Dosage Calculation:  D = 100 (C1/T1 + C2/T2 + C3/T3 +…)  D > 50% requires hearing protection  D > 80% requires engineering intervention

Engineering Analysis: Machine Guarding General Industry (29 CFR 1910)29 CFR (d)(44) "Pinch point" means any point other than the point of operation at which it is possible for a part of the body to be caught between the moving parts of a press or auxiliary equipment, or between moving and stationary parts of a press or auxiliary equipment or between the material and moving part or parts of the press or auxiliary equipment (a)(1) Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc. Plus specifics for Electrical Markings, Lubrication Access, Belts, and more

Engineering Analysis: Costs CategoryCost Raw Materials$850 Motor$900 Belt-Drive System$100 Control system$1,000 Display$250 System to calibrate displacement$300 Rust Prevention$300 Total$3,700

Schedule for Next Phase

Questions?

Appendix /Reference Information Laser Sensor Long Range/High Accuracy Sensor LK-G152/G157 Series Range: 150 +/- 40mm Accuracy: +/-0.05% Sensor Speed: 50kHz Repeatability: 0.5µm Sources e/laser-1d/lk- g3000/applications/application-04.jsp e/laser-1d/lk- g3000/applications/application-04.jsp ry/sensors/displacement- sensors_measurement-sensors/index.html ry/sensors/displacement- sensors_measurement-sensors/index.html

More Motor Information V-Belt Life: 25,000 hours (714 testing cycles)

Alternatives Considered:

Full Risk Assessment

Safety Checklist